4 case 4 case studies to discover studies to discover

the the possible possible automotive applications automotive applications of glass microspheres of glass microspheres
Frdric Juprelle
Business Unit Manager
Technical Products
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I. General introduction about glass beads
II. Case studies
1. How does BMW improve aesthetic & dimensional stability of PA - 30% glass
fibers?
2. How to improve aesthetic and scratch resistance in PP in PSA application?
3. How does LG enhance dimensional stability & surface resistance in ABS 20%
Agenda Agenda
3. How does LG enhance dimensional stability & surface resistance in ABS 20%
glass fibers?
4. What can the new E-glass grade bring to Polycarbonate resin producers?
III. Conclusion
2
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I. General introduction about glass beads
II. Case studies
1. How does BMW improve aesthetic & dimensional stability of PA - 30% glass
fibers?
2. How to improve aesthetic and scratch resistance in PP in PSA application?
3. How does LG enhance dimensional stability & surface resistance in ABS 20%
Agenda Agenda
3. How does LG enhance dimensional stability & surface resistance in ABS 20%
glass fibers?
4. What can the new E-glass grade bring to Polycarbonate resin producers?
III. Conclusion
3
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Sovitec in Figures Sovitec in Figures
#1 solid glass beads producer in Europe #1 solid glass beads producer in Europe
1954 1954 58 years of experience 58 years of experience
5 production sites 5 production sites 100,000 T capacity 100,000 T capacity
160 employees 160 employees
4
Charleroi - BE
Buenos Aires - AG
Berlin - GE
Barcelona - ES
Metz - FR
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Road Marking: 400 2,000m
Blasting: 50 500m
Functional filler in plastics and coatings: 1 50m
Efficient Coupling Agents for a wide resin portfolio:
PA, PUR, Epoxy, PBT, PET, Polyester, Vinylester, PE, PP
and now Styrenics & Polycarbonate
Sovitec portfolio and field of expertise Sovitec portfolio and field of expertise
and now Styrenics & Polycarbonate
Processing mastery for well controlled particle size
Microperl

: 20 to 40m
Omicron

: 3 to 5m unique GB producer to produce this particle size

5
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Sovitecs Sovitecs Glass Beads Glass Beads
6
Raw Material =
Recycled glass
SPE ANTEC

2014 / 156
I. General introduction about glass beads
II. Case studies
1. How does BMW improve aesthetic & dimensional stability of PA - 30% glass
fibers?
2. How to improve aesthetic and scratch resistance in PP in PSA application?
3. How does LG enhance dimensional stability & surface resistance in ABS 20%
Agenda Agenda
3. How does LG enhance dimensional stability & surface resistance in ABS 20%
glass fibers?
4. What can the new E-glass grade bring to Polycarbonate resin producers?
III. Conclusion
7
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Case Study 1: PA6 Case Study 1: PA6--GF GF Starting point Starting point
Company: BMW
Market: Automotive
Material: PA6 + 30% glass fibers
Processing mode: Twin-screw extrusion and injection molding
Requirements: Requirements:
Improve surface aspect and dimensional stability
white powdered surface due to fibers
unstable shrinkage and warpage
Maintain good mechanical properties
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Case Study 1: Case Study 1: PA6 PA6--GF GF Solution & Benefits Solution & Benefits
Solution: substitute 1/3 of glass fibers by solid glass beads
Initial material: PA6 + 30% glass fibers
Final material: PA6 + 20% glass fiber + 10% Microperl

050-20-215 (20m)
Benefits:
Surface improvement no white powder on the surface anymore Surface improvement no white powder on the surface anymore
Good Dimensional stability warpage and shrinkage are now more stable
Mechanical performance brought by glass fibers are retained
Additional benefits:
Higher production output
Cost reduction
Improved abrasion resistance
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Case Study 1: Case Study 1: PA6 PA6--GF GF Technical Data Technical Data
Surface improvement
PA + 20% GF + 10% GB PA + 30% GF Glass fibers are dispersed
Leading to powdered surface
Beads align the fibers,
leading to clean surface
Better dimensional stability
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GB influence on Warpage
0
20
40
60
80
100
120
140
160
PA PA + 30%
GF
PA +
30%GB/GF
PA +
30%GB
F
l
o
w
- 47%
GB influence on Shrinkage
0
0,05
0,1
0,15
0,2
0,25
0,3
0,35
0,4
FLOW TRANSVERSAL
p
e
r
c
e
n
t
a
g
e
PA6
30% GF
30% GB/GF
30% GB
- 33%
- 25%
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Case Study 1: Case Study 1: PA6 PA6--GF GF Technical Data Technical Data
Keep good mechanical properties
Property Units Method PA6 30% GF 30% GB/GF
Izod Impact
(unnotched)
kJ/m ISO 180/1U n.b. 90 75
Izod Impact
(notched)
kJ/m ISO 180/1A 8 6 6
Flexural Modulus MPa ISO 178 2900 8000 7400
Flexural Strength MPa ISO 178 125 155 145
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Tensile Modulus MPa ISO 527-2 3200 9200 8700
Elongation at break % ISO 527-2 4,5 3 4
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Case Study 1: Case Study 1: PA6 PA6--GF GF Technical Data Technical Data
Additional Benefits measured
Higher production output
-14% on cycle time
Cost reduction
-2,4% on raw material cost
50
60
70
80
90
100
110
750 800 850 900 950 1000
T
o
r
q
u
e
Production output (kg/h)
Production output
PA 6.6 + 30% GF
PA 6.6 + 20% GF
+ 10% GB
PA 6.6 + 10% GF
+ 20% GB
PA 6.6 + 30% GB
Compound RM cost
PA6 + 30%GF 2680 /T
-2,4% on raw material cost
Improved abrasion resistance
+1,5% on weight retained
12
98,5
98
99,5
99,9
97
97,5
98
98,5
99
99,5
100
100,5
PA6 30% GF 30% GB/GF 30% GB
Weight retained after testing (%)
+1,5%
PA6 + 30%GF 2680 /T
PA6+20%GF+10%GB 2615 /T
SPE ANTEC

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I. General introduction about glass beads
II. Case studies
1. How does BMW improve aesthetic & dimensional stability of PA - 30% glass
fibers?
2. How to improve aesthetic and scratch resistance in PP in PSA application?
3. How does LG enhance dimensional stability & surface resistance in ABS 20%
Agenda Agenda
3. How does LG enhance dimensional stability & surface resistance in ABS 20%
glass fibers?
4. What can the new E-glass grade bring to Polycarbonate resin producers?
III. Conclusion
13
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Case Study Case Study 2: PP 2: PP Starting point Starting point
Company: PSA
Market: Door handles, dashboard,
Material: PP + 30% Talcum
Processing mode: Twin-screw extrusion and injection molding
Requirements
Improve dimensional stability
Improve abrasion and scratch resistance
Improve aesthetic
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Case Study Case Study 2: PP 2: PP Solution & Benefits Solution & Benefits
Solution: Sovitec developed a new family of coupling agent giving both the link with
glass and polyolefin resin.
Now it is possible to achieve similar results shown on PA in reinforced PP
Initial material: PP + 30% Talcum
Final material: PP + 15% Talcum and 15% Microperl

050-20-223 (20m)
Benefits:
Better dimensional stability lower and isotropic shrinkage
Better abrasion and scratch resistance more durable surface aspect
Better surface aspect
15
Previous PP grade New PP grade
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Case Study Case Study 2: PP 2: PP Technical Data Technical Data
Better Dimensional Stability : Shrinkage properties
0,5
1
1,5
2
%
PP
30%
TALCUM
30% GB
223
Better abrasion resistance
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Taber Test
CS10 1kg
PP + 30% Talcum
(weight lost)
PC + 15% Talcum+ 15% GB
(weight lost)
1000 cycles 48 mg 24 mg
5000 cycles 230 mg 95 mg
10000 cycles Destroyed 160 mg
0
0,5
FLOW TRANSVERSAL
15%
Talcum &
15% GB223
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Case Study Case Study 2: PP 2: PP Technical Data Technical Data
Higher scratch resistance
20
40
60
80
100
PP
30% Talcum
30% GB 223
15% Talcum &
15% GB223
Aesthetic
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0
20
ISO1518 (2 kg)
100 = no visible scratch 80 = low scratch 60 = medium scratch 40 = depth scratch 20 = very depth scratch
PP + 30% Talcum PP + 15% Talcum+ 15% GB
SPE ANTEC

2014 / 167
I. General introduction about glass beads
II. Case studies
1. How does BMW improve aesthetic & dimensional stability of PA - 30% glass
fibers?
2. How to improve aesthetic and scratch resistance in PP in PSA application?
3. How does LG enhance dimensional stability & surface resistance in ABS 20%
Agenda Agenda
3. How does LG enhance dimensional stability & surface resistance in ABS 20%
glass fibers?
4. What can the new E-glass grade bring to Polycarbonate resin producers?
III. Conclusion
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Case Study 3: ABS Case Study 3: ABS--GF GF Starting point Starting point
Company: LG
Market: Electronic device housing
Material: ABS + 20% GF
Processing mode: Twin-screw extrusion and injection molding
Requirements
Improve dimensional stability
Improve abrasion and scratch resistance
Improve surface aspect
Maintain mechanical properties
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Case Study 3: Case Study 3: ABS ABS--GF GF Solution & Benefits Solution & Benefits
Solution: add 10% of glass microspheres
Initial material: ABS + 20% GF
Final material: ABS + 20% GF + 10% Microperl

050-20-215 (20m)
Benefits:
Better dimensional stability lower and isotropic shrinkage Better dimensional stability lower and isotropic shrinkage
Better abrasion and scratch resistance more durable surface aspect
Surface aspect glass fibers/glass beads dispersion improved
Similar mechanical performance
Additional benefits:
Higher production output
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Case Study 3: ABS Case Study 3: ABS--GF GF Technical Data Technical Data
Lower and isotropic shrinkage
Better scratch resistance
Sample ABS ABS + 20% GF ABS + 20% GF + 10% GB ABS + 20% GB
Shrinkage (parallel) 0,80 % 0,50 % 0,40 % 0,20 %
Shrinkage (perpendicular) 1,00 % 0,70 % 0,40 % 0,20 %
ABS + 20% GF + 10% GB ABS + 20% GF
Better abrasion resistance
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Scratch done with a Clemen, 2kg Weight, Tungsten bead
ABS ABS + 20% GF ABS + 20% GF + 10% GB ABS + 20% GB
Weight lost (%) 2,3 2,8 1,7 0,9
Abrasion done with an abrasive paper 40, 10000 cycles
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Case Study 3: Case Study 3: ABS ABS--GF GF Technical Data Technical Data
Better Surface aspect
ABS+20%GF+10% GB
ABS+20%GF
Clean surface aspect
due the dispersion of
glass fiber
Mechanical performance are retained
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Property Units Method ABS 20% GF 20% GF 10% GB
Charpy Impact (unnotched) kJ/m ISO 180/1U n.a. 22 22
Charpy Impact (notched) kJ/m ISO 180/1A 12 12 10
Flexural Modulus MPa ISO 178 2370 5000 5200
Flexural Strength MPa ISO 178 62 125 125
Tensile Strength MPa ISO 527-2 38 90 95
Elongation at break % ISO 527-2 15 4 8
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Case Study 3: Case Study 3: ABS ABS--GF GF Technical Data Technical Data
Additional Benefits measured
Higher production output
60
70
80
90
100
110
120
T
o
r
q
u
e
ABS + 20% GF
ABS + 20%GF +
10%GB
ABS + 20% GB
At same torque higher
production output
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ABS + 20% GF ABS + 20% GF + 10% GB ABS + 20% GB
Cycle Time 50 seconds 45 seconds 39 seconds
Saving 5 seconds (10%) 11 seconds (22%)
50
60
750 800 850 900 950 1000
Speed (kg/h)
ABS + 20% GB
10 to 22% shorter cycle
time measured
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I. General introduction about glass beads
II. Case studies
1. How does BMW improve aesthetic & dimensional stability of PA - 30% glass
fibers?
2. How to improve aesthetic and scratch resistance in PP in PSA application?
3. How does LG enhance dimensional stability & surface resistance in ABS 20%
Agenda Agenda
3. How does LG enhance dimensional stability & surface resistance in ABS 20%
glass fibers?
4. What can the new E-glass grade bring to Polycarbonate resin producers?
III. Conclusion
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Case Study 4: New grade for PC Case Study 4: New grade for PC Starting point Starting point
Company: -
Market: Various applications Suitcases, Cars, electronic,
Material: PC
Processing mode: Twin-screw extrusion and injection molding
Requirements
Improve dimensional stability
Improve abrasion and scratch resistance
Improve processing
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Case Study 4: New grade for Case Study 4: New grade for PC PC Solution & Benefits Solution & Benefits
Solution: Sovitec developed a new glass composition to answer OEM customer request
The chemical structure of E-glass naturally leads to higher compatibility between the
resins and the beads.
Initial material: PC
Final material: PC + 15% of Microperl

050-20-EG (20m)
Benefits:
Better dimensional stability lower and isotropic shrinkage
Better abrasion and scratch resistance more durable surface aspect
Easier processing
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Case Study 4: New grade for Case Study 4: New grade for PC PC Technical Data Technical Data
Easier processing
The addition of glass beads clearly improve the extrusion and injection of PC compounds : ball bearing
effect, less defects,
To produce 500 pieces within specifications
Formulation Cycle Time
Nb of injected
pieces
Total time for this
production
PC 44s 512 375 min
PC + 15% GF 48s 552 442 min
Better abrasion resistance
27
PC + 15% GF 48s 552 442 min
PC + 15% GB 36s 501 300 min
Taber Test
CS10 1kg
PC
(weight lost)
PC + 15% GB
(weight lost)
1000 cycles 30 mg 5 mg
5000 cycles 180 mg 30 mg
10000 cycles Destroyed 65 mg
64% more resistant than PC
for 2x cycles
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Case Study 4: New grade for Case Study 4: New grade for PC PC Technical Data Technical Data
Higher scratch resistance
PC + 15% GB PC
Better dimensional stability
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0
20
40
60
80
100
120
140
PC PC + 15% GF PC + 15% GB
Warpage (%)
- 55%
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Benefits of Glass Benefits of Glass Beads Beads -- Conclusion Conclusion
Glass microspheres offer a wide set of technical and economic advantages, alone or
blend to your current solution.
By substituting a portion of GF, or replacing silica by microspheres into several
thermoplastic resins (PA / PP / PO / PBT / Styrenics / PC), we improve the following
properties :
Dimensional Stability: warpage, shrinkage and isotropic behavior
Surface aesthetic: uniform color and aspect
Scratch & Abrasion resistance: shallower scratch & excellent abrasion resistance
Processing speed: production output (extrusion, injection, film, ) & less waste
Cost reduction: cost-savings

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Thank you for your attention Thank you for your attention
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